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How hard is it? I have the dreaded roof rail corrosion and am considering removing and repainting the rack myself.
How big a deal is taking out the headliner? I can see that the OH console, mirrors, grabs, etc all need to be detached, and the trim on the pillars removed.

Anyone done it? How long should I budget? (competent amateur mechanic, and i want it to go back together correctly.
Thanks for any help. I have searched for DIYs but haven't found any.

Hi Greg , I know I have seen a couple of people have done this, and had hoped they could give you a time frame…I haven’t … but I can send you the instructions if you wish ( just too large to post it all here )
So send me a private msg. with your email if you are interested, and I’ll try and get it off to you..
This looks like a fun but time consuming job. It includes removal of; both sun visors & supports, all handles, all trim panels from all pillar’s, trims, & all ceiling lights…
Also, tell me if you don’t have the panorama sunroof
John

The rear panel on the panoramic sunroof jammed open on my wife's E83. Could use the same info to remove the headliner - sending you a private message to that effect as well if you still have those instructions available.

It's not very difficult.. I removed rear to get access to shark fin, all pilar covers have to come off. There are two screws holding each of oh sit handles, with each screw hidden with a snap in cover. Those things were a bit of a pain, but once you get first one out, it is simple. There is usually a Torx screw behind Srs bracket. Take your time, it can be removed in under 2 hours..

took out an 04 in~90 mins ....lots of plastic clips need a firm yank just like pulling the bench on the rear seat.....most important thing was an assistant .....when it comes free it's a bit of a large boat sail BUT quite rigid .....just need a good pal to help slide it out so it doesn't get soiled or dinged....be ready with a nice clean spot to lay it down
also ....check the pano roof rear drain lines while at it .....both of these were kinked at about elbow height on a six footer at the rear door .......an electricians fish tape works well to snake down the drain lines for and aft
also ....if the kinks won't stay out you can cut the plastic line either side of the kink and work in a pvc sleeve to provide a full diameter path to drain